Design & Analysis Of Different Materials For Drill Jig .

e-ISSN: 2582-5208International Research Journal of Modernization in Engineering Technology and Science( Peer-Reviewed, Open Access, Fully Refereed International Journal )Volume:03/Issue:11/November-2021Impact Factor- 6.752www.irjmets.comDESIGN & ANALYSIS OF DIFFERENT MATERIALS FOR DRILL JIGAPPLICATIONSHimank Dugtal*1*1MEStudent, Department Of Mechanical Engineering, Osmania University,Hyderabad, Telangana, India.ABSTRACTThe project consists of design & analysis of different materials for drill jig applications. The modelling of drill jigis made on the CATIA software & analysis is done on Ansys. Material taken for the analysis are Aluminum, Castiron & Low carbon steel. Static structural analysis was carried out on the drill jig of 4 hole for three completelydifferent materials. Use of drilling jig increases the assembly rate with good quality and accuracy. The staticstructural analysis was done at totally different load conditions for various materials and results are tabulatedin the graphs. The modelling of the individual components and also the assembly of the individual componentswas module by bottom up methodology. These individual parts are then brought together within the assemblywith proper mating sequences. After the assembly, the analysis is performed.Keywords: Drill Jig, Applications, Static Analysis.I.INTRODUCTIONTool designers cares with design and development of machines and special tooling, strategies and techniquesneeded by today’s high speed mass manufacture at high potency and productivity. Its main objective is tosupply element at a competitive value, maintaining quality and accrued production. Design of tools to be proofwith no chance of wrong operation, quality consciousness in any respect level. The first objective of theutilization of jigs and fixtures is to facilitate the holding and supporting of the element by using fixtures,position it properly and guide the cutters in order that each element are uniform.Jigs and FixturesPrimary function of a jig is to make accurately drilling holes without wear & tear. Jigs and fixtures aremanufacturing tools which are used to provide interchangeable and identical components. They are uniquetool-guiding and work-holding devices designed specifically for machining and assembling sizable amount ofparts. The need of jigs and fixtures reduction of cost, increase of production rate, high accuracy of products withnone manufacturing defects, provision of interchangeability, easy machining of complex shaped parts,reduction of control costs, etc. Jigs and fixtures minimizes the scope for a special acknowledged for every workpiece thereby facilitating production and also ensuring that every work piece is manufactured within apredetermined tolerance.That the foremost advantages of Jigs and fixtures are durability, setup reduction, improvement in productivity,reduced deciding operational selected from the standard components. The main difference between a jig and afixture is that jigs guide the cutter to its precise position, also as locating and supporting the work-piece duringthe entire operations.The essential features of jigs and features includes: Clamps position Neatness of work-piece Standardization Idle time reductionDrilling Jigs: Drilling jigs usually is to create machine holes on mechanical products to urge positional accuracyof the holes harden drill bushes or jig bushes for locating, guide drills and reamers etc. In regard to the workpiece these guide bushes aren't essential but these convinced to be economical and technically desirable. Theposition of the jig into which the harden bushes were fitted known as bushing plate. If one hole is to be drilled,the drill jig is made to slide on the table to drilling machine. If the drill size is large enough to provide a hightorque, either stops should be provided or the drill jig is clamped to the table of the drilling machine. A drill jigwww.irjmets.com@International Research Journal of Modernization in Engineering, Technology and Science[735]

e-ISSN: 2582-5208International Research Journal of Modernization in Engineering Technology and Science( Peer-Reviewed, Open Access, Fully Refereed International Journal )Volume:03/Issue:11/November-2021Impact Factor- 6.752www.irjmets.comis given feet which rest or slide on the table of drilling machine. Drilling jig makes an ease on drilling of holes athigher speed with greater accuracy and with less skilled worker. Also they produce inter changeable partsbecause each part drilled during a drilling jig should have the identical hole pattern as every other parts.It is clear that within the drilling operations burs are getting to be produced. The bur produced at the in need ofthe opening is smaller than that produced at the highest of the opening . The first type is known as minor bursand second type is known as major bur. Few examples of drilling jigs are: Template jig, sandwich jig, Angularplate jig, pot jig, Plate type jig, box type jig, channel type jig etc.Figure 1: Sandwich jigFigure 2: Angle plate jigII.Figure 3: Indexing jigMETHODOLOGYTable 1: Specification of Drill JigSN.NOPARAMETERSDIMENSION1Drill jig inner dia20 mm2Outer dia112 mm3Thickness5 mm4Shaft length250.6 mm5Shaft dia20 mmDesign of a Drill jig with 4 holeFigure 4: 3D Model of Strap ClampFigure 5: 3D Model of Linear BushFigure 6: 3D Model of Renewable Bushwww.irjmets.com@International Research Journal of Modernization in Engineering, Technology and Science[736]

e-ISSN: 2582-5208International Research Journal of Modernization in Engineering Technology and Science( Peer-Reviewed, Open Access, Fully Refereed International Journal )Volume:03/Issue:11/November-2021Impact Factor- 6.752www.irjmets.comIII.MODELING AND ANALYSISTable 2: Material properties used in drill jigPropertiesDensity (g/)Poisson’s ratioYoung’s modulus(GPa)Yield strength (MPa)Cast Iron7.850.3380250Low Carbon Steel7.75 e-0060.3324207Aluminum2.77 e-0060.3386280Static Structural & Modal Analysis for 4 holes Drill jigAfter the importing of model into a project schematic window layout drag. Drop the static structural tab ontothe screen from the toolbox window and link the geometry to geometry both are going to be linked together &then Double click on the model it will open the mechanical window which was imported into the geometrysection. Further uncheck the transparent mode.www.irjmets.com@International Research Journal of Modernization in Engineering, Technology and Science[737]

e-ISSN: 2582-5208International Research Journal of Modernization in Engineering Technology and Science( Peer-Reviewed, Open Access, Fully Refereed International Journal )Volume:03/Issue:11/November-2021Impact Factor- 6.752www.irjmets.comCast IronLow Carbon SteelAluminumwww.irjmets.com@International Research Journal of Modernization in Engineering, Technology and Science[738]

e-ISSN: 2582-5208International Research Journal of Modernization in Engineering Technology and Science( Peer-Reviewed, Open Access, Fully Refereed International Journal )Volume:03/Issue:11/November-2021Impact Factor- 6.752www.irjmets.comFigure 24: Equivalent StressIV.RESULTS AND DISCUSSIONTable 3: Static Structural Analysis 4 Holes, F 500 NS.No.MaterialTotal DeformationEquivalent StressEquivalent Strain1Cast Iron2.4365e.0043.9878e.60.438422Low Carbon 046.2274e.60.44913Figure 25: Static Structural Analysis 4 Holes , F 500 NV.CONCLUSIONModelling and analysis was completed by using Catia and Ansys software respectively. A static structuralanalysis was carried out on the 4-hole for 3 completely different materials and results were obtained. In linewith the results stress may be almost shut for 3 materials however considering deformation is a smalleramount for Aluminum compared with cast iron and low carbon steel. Hence the design made satisfies theinterchangeable part concepts & thus the design is validated & fool proof. Thus the Aluminum is best materialfor the manufacturing such drill jig & weight is additionally lighter as compared with low carbon steel & castiron. This not only increases the speed of production but also decreases the quantity of labor that wasperformed for adjusting the work piece for drilling operation in conventional method. Also maximum accuracyand reliability is achieved which wasn't possible with the assistance of traditional methods.VI.[1]REFERENCESK.Rama Subba Reddy, S.Ramesh Kumar Babu “Design and Analysis of Drill Jig at Variable Materials”International Research Journal of Engineering and Technology (IRJET) Volume: 03 Issue: 06, June-2016www.irjmets.com@International Research Journal of Modernization in Engineering, Technology and Science[739]

e-ISSN: 2582-5208International Research Journal of Modernization in Engineering Technology and Science( Peer-Reviewed, Open Access, Fully Refereed International Journal )Volume:03/Issue:11/November-2021Impact Factor- 6.752www.irjmets.com[2]Midhun. R, Vignesh.A “Design and Fabrication of Jigs and Fixtures for Drilling Operation” IJSRD International Journal for Scientific Research & Development R, Vignesh.A “Design and Fabrication ofJigs and Fixtures for Drilling Operation” IJSRD -International Journal for research project &Development , Vol. 3, Issue 12, 2016[3]Design and analysis of work holding fixture by Shivaji popat Mengawade, Vaibhav banker, Pratik IJSRD,vol.4,issue 06, 2016, ISSN:2361-0613[4]Nirav Newar, K. S. Chaitnaya, Phani Shankar, “Modelling and Analysis of Drill Jig”, International Journalof Innovative Technologies (IJITECH) R, Vignesh.A “Design and Fabrication of Jigs and Fixtures forDrilling Operation” IJSRD -International Journal for research project & Development Vol. 3 Issue 10,November-2015, Pages- 1838-1844P.Stephen Antony Predeep, S. Sivason Raja, C. Rammurugan “Optimizing the Method of Work HoldingDevice-Drill Jig with Adjustable Drill Bush” International Journal of Innovative Research in Science,Engineering and Technology,R, Vignesh.A “Design and Fabrication of Jigs and Fixtures for DrillingOperation” IJSRD -International Journal for research project & Development, Vol. 4, Special Issue 6,May 2015NBV Lakshmi Kumari, G. Prsasnna Kumar, “Design and Analysis of Indexing sort of Drill Jig”, IOSRJournal of Mechanical and engineering (IOSR-JMCE) e-ISSN: 2278-1684, p-ISSN: 2320-334X, Volume12, Issue 2 Ver. I (Mar - Apr. 2015), PP 46-51Shivanand Vathare, Shrinivas L Gombi, Darshan M Katgeri “Design and Analysis of Drill Jig for Head andCover Part of the Actuator”, IJERT Volume 03, Issue 08 (August 2014) IJERTV3IS080184Taufik, R.S.; Hirmanto, S.; Sivarao, Hambali, A. and Tajul, A. A., (2012): Design of Jigs and Fixtures forpress Machine” Malikussaleh industrial management Journal Vo.1 No.1 (19-24) ISSN 2301 934.[5][6][7][8]www.irjmets.com@International Research Journal of Modernization in Engineering, Technology and Science[740]

position of the jig into which the harden bushes were fitted known as bushing plate. If one hole is to be drilled, the drill jig is made to slide on the table to drilling machine. If the drill size is large enough to provide a high torque, either stops should be provided or the drill jig is clamped to the table of the drilling machine. A drill jig